Soda Ash Control - Sterling Systems and Controls https://www.sterlingcontrols.

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Soda ash, or sodium carbonate (NA2CO3) is a water soluable salt of carbonic acid. It is
often used in municipal water treatment to raise the pH of the water. “Historically sodium
carbonate was extracted from the ashes of plants growing in sodium-rich soils, such as
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vegetation from the Middle East, kelp from Scotland and seaweed from Spain. Because the
ashes of these sodium-rich plants were noticeably different from ashes of timber (used to
create potash), they became known as soda ash” – source WikPedia. Soda ash control is
an important aspect in the use of soda ash.

This soda ash control application is in a municipal water treatment facility. In this
application Sterling Systems & Controls worked with the construction contractor and end
user (municipality) to provide a control system and automation for the soda ash processing
and handling equipment. The control system consists of a stainless steel NEMA4X PLC
Control Panel that contains a Main Disconnect, E-Stop button, Alarm Horn and Beacon,
Alarm Silence button, and a 6” PanelView Compact Color Touchscreen HMI. A second
control panel is also included, a stainless steel NEMA4X Silo Fill Control Panel which
contains Manual/Off/Auto (MOA) switches, indicator lights, and Alarm Horn. Indicator lights
notify the operator of silo levels and the status of selected equipment. An alarm horn
notifies the operator of all urgent or abnormal conditions. The horn can be silenced at any
time via an alarm silence pushbutton as well as from the HMI.

MOA switches on the Silo Fill Control Panel provide manual-off-auto operation for selected
equipment. A switch must be placed in the automatic position for the PLC to control the
corresponding equipment automatically. When MOA switches are placed in automatic
mode, the system is operated by setpoints and system parameters entered into the HMI
and pressing the on-screen Start pushbuttons to enable automatic operation of the selected
process. When the system is enabled and in automatic mode, it will control the Slurry
Refill, Silo Filling, and Slurry Injection processes as described below.

The soda ash control system is started as follows:

1. The Operator ensures that the Emergency Stop (E-Stop) is pulled out and the system
is powered

up and ready. Using the

Touchscreen HMI, the operator
places all equipment in Automatic
Mode using each items MOA
switch.

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2. As long as the E-Stop is

pulled out and the Agitator is
not in Off Mode, the Agitator Silo Refill Screen

will run continuously.

3. The operator verifies and adjusts the initial Screw Feeder speed setpoint (feed rate)
on the Touchscreen HMI as necessary.

4. The operator presses the on-screen Slurry Refill Start pushbutton.

5. The System will evaluate the Anti-Blockage switch (AB) and confirm that there is no
blockage. If a blockage is detected an alarm will be generated and no equipment will
be started.

6. If the Silo Security Level (low level) is indicating a security level, the system will
generate an alarm and no equipment will be started.

7. If the Slurry Tank High Level is indicating a high level condition, the system will
generate an alarm and no equipment will be started.

8. If the Slurry Tank Batch Level is indicating that the level in the tank is at or below the
batch level, but not at or below the Slurry Tank Low Level, the system will start the
Injector Motor and confirm that it is running. A short programmable Spin-Up timer will
be started.

9. When the Spin-Up Timer expires the system will open the Water Supply Solenoid
Valve.

10. The system will simultaneously start the Screw Feeder and Arch Breaker.

11. The speed of the Screw Feeder is determined by an initial setpoint on the
Touchscreen HMI, which can be changed in real-time at any time from the process
screen. System Parameters are provided to define the Maximum and Minimum
allowable speed setpoints.

12. The Touchscreen HMI displays the status of the equipment on the screen and
indicates that the system is running.

The equipment will be stopped in the following manner.

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1. Equipment can be stopped in one of eight ways:

1. By Pressing the E-Stop button. This will electrically turn off all
equipment immediately and stop the system.

2. By Pressing the Slurry Refill Stop pushbutton on the Touchscreen HMI.

This causes the system to shutdown as described below and Disables
the system until the Start pushbutton is pressed again.

3. By Detecting the Silo Security Level (low level). System will attempt to
resolve any product bridging by running the silo vibrators for a
programmable amount of time. If the SLS condition still exists,
equipment will be shut down as described below and the system is
Disabled until the condition has been corrected, and the Start
pushbutton is pressed again.

4. By Detecting the Slurry Tank High Level. Equipment is shut down as

described below and the system remains enabled, but idle until the
Slurry Tank Batch Level is detected.

5. By Detecting the Slurry Tank Low Level. Equipment will be shut down
immediately. The system is Disabled until the condition has been
corrected and the Start pushbutton is pressed again. Note: The process
can start when there is a Slurry Tank Low Level condition, but once the
slurry surpasses this level and falls back below, the alarm is triggered
and the equipment is shut down immediately.

6. By Detecting a signal on the Anti-Blockage switch. Equipment is shut

down as described below. The system is Disabled until the condition
has been corrected and the Start pushbutton is pressed again.

7. By Detecting that the Agitator is not running. Equipment is shut down

immediately. The system is Disabled until the condition has been
corrected and the Start pushbutton is pressed again.

8. By Detecting that the Screw Feeder is not rotating, from the Rotation
Sensor. Equipment is stopped immediately.

2. Once the system determines it is time to shut down the equipment, based on one of
the conditions listed above, it turns off the Arch Breaker and Screw Feeder
immediately.
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3. The Water Supply Solenoid Valve is also closed and the system starts a
programmable Purge Timer for the Injector Screw.

4. Once the Screw Feeder Purge Timer expires the system will turn off the Injector
Screw.

Automation of the following processes

also exists in this system:

Silo Filling Startup

Silo Filling Shutdown

Slurry Injection Startup

Slurry Injection Shutdown

System Alarms
Silo Filling SCreen
Manual Control

Manual Interlocking Rules

System Parameters

Sterling, IL: For Immediate Release. Sterling Systems & Controls, Inc. is pleased to
announce the …

Sterling, IL: For Immediate Release. Sterling Systems & Controls, Inc. is pleased to
announce that …

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P.O. Box 418

24711 Emerson Rd.

Sterling, IL 61081

Toll Free: 1-800-257-7214

Local Phone: 1-815-625-0852
Fax: 815-625-3103

sci@sterlingcontrols.com

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